Sign up to receive free email alerts when patent applications with chosen keywords are publishedSIGN UP

Abstract:

An electrode cap having a horseshoe-shaped conductor clip that has an
opening at a closed end for receiving an electrode, the conductor clip
fitted over a tube crimp; a cylindrical base cap having an elongated bump
at one end of the base cap parallel to the axis of the base cap; and a
cylindrical top cap closed on one end, having an inside diameter larger
than the outside diameter of the base cap; and a spring for pressing a
plate against the base cap.

Claims:

1. An electrode cap for removably securing an electrode to a plate
comprising:a horseshoe-shaped conductor clip comprising an opening at a
closed end for receiving an electrode, the conductor clip adapted to fit
over a tube crimp;a substantially cylindrical base cap comprising an
elongated bump at one end of the base cap parallel to the axis of the
base cap;a substantially cylindrical top cap closed on one end, having an
inside diameter larger than the outside diameter of the base cap; anda
spring means for pressing a plate against the base cap.

2. The electrode cap of claim 1, the base cap further comprising an
external flap extending toward the bump.

3. The electrode cap of claim 2, the top cap further comprising a window
sized to receive and retain the base cap flap and to provide an
electrical connection when assembled.

4. The electrode cap of claim 1, wherein the spring means is a wave
spring.

5. The electrode cap of claim 1, wherein the conductor clip, base cap, top
cap, and spring means are made from an electrically conductive material.

6. The electrode cap of claim 1, further comprising a helical compression
cap spring having an outside diameter smaller than the top cap inside
diameter for providing compression and electrical connection between the
top cap and the conductor clip when assembled.

7. The electrode cap of claim 6, further comprising an electrically
conductive plate for removably securing the electrode and providing
electricity.

8. The electrode cap of claim 6, wherein the junction of the top cap
diameter and closed end is rounded to prevent the formation of corona in
operation.

9. The electrode cap of claim 6, further comprising:a tube;a crimp at one
end of the tube; andan electrode disposed within the tube and crimp
adapted to be coupled with the conductor clip.

10. A method of removably securing an electrode in a place comprising the
steps of:providing an electrode tube comprising a tube, a crimp at one
end of the tube, and an electrode disposed within the tube and
crimp;placing a horseshoe-shaped conductor clip over the crimp;securing
the electrode to the conductor clip;placing a substantially cylindrical
base cap over the tube at the crimp end, the base cap having an elongated
bump at one end of the base cap parallel to the axis of the base cap, and
having an external flap extending toward the bump;placing a helical
compression cap spring inside the base cap and in contact with the
conductor clip;assembling a substantially cylindrical top cap that is
closed on one end, having an inside diameter larger than the outside
diameter of the base cap and having a window sized to receive and retain
the base cap flap, so that the base cap flap engages the window and
locks;assembling a wave spring over the base cap;inserting the electrode
assembly into a plate having a hole to receive the base cap and a groove
to receive the bump; andtwisting the electrode assembly to lock it in
place.

Description:

BACKGROUND

[0001]1. Field of the Invention

[0002]The invention is in the field of electrical discharge reactors.

[0003]2. Description of the Related Art

[0004]Electrical discharge reactors are used in ozone generators, UV
disinfection devices, and pollution control devices. An example is
described in U.S. Pat. No. 6,132,692, which is not admitted to being
prior art by its mention in this Background section. Some of the
different types of electrical discharges include glow, corona, and
dielectric barrier discharge.

[0005]Some of the common parts of dielectric barrier discharge reactors
include a high voltage electrode, which is usually a wire or thin rod.
This is disposed inside a tube that is typically made of glass or fused
quartz. The tube forms the dielectric barrier. The inside of the tube may
be filled with a gas, air, or a vacuum.

[0006]Reactors are made by providing a plurality of tube and electrode
assemblies physically and electrically connected to plates. In the past,
the electrode assemblies were capped with a metal cap on one end and
secured to the plate with an extension and a screw. The electrode wire
sticks out the end of the cap, and can be secured by welding.

[0007]This configuration has several disadvantages. First, centering the
electrode assembly is not assured, and misalignment is possible. It is
also difficult to secure the screws if there are many electrode
assemblies close together. The electrode must make a sharp bend, which
may damage it. Furthermore, the sharp end of the wire and corners of the
cap might generate corona, which must be avoided. The tube seal is also
susceptible to damage from vibration and rough handling. Finally, the old
configuration does not allow for thermal expansion. These disadvantages
tend to cause breakage and failure of the electrode.

[0008]What is needed, therefore, is an electrode cap for an electrical
discharge reactor that is easy to install, assures proper alignment,
inhibits corona, provides some cushion to avoid damages, and permits
thermal expansion.

SUMMARY

[0009]The invention is an apparatus that satisfies the need for an
electrode cap for an electrical discharge reactor that is easy to
install, assures proper alignment, inhibits corona, provides some cushion
to avoid damages, and permits thermal expansion. The invention is an
electrode cap comprising a horseshoe-shaped conductor clip comprising an
opening at a closed end for receiving an electrode, the conductor clip
adapted to fit over a tube crimp; a substantially cylindrical base cap
comprising an elongated bump at one end of the base cap parallel to the
axis of the base cap; and a substantially cylindrical top cap closed on
one end, having an inside diameter larger than the outside diameter of
the base cap; and a spring means for pressing a plate against the base
cap. These and other features, aspects, and advantages of the present
invention will become better understood with regard to the following
description, claims, and accompanying drawings.

DRAWINGS

[0010]FIG. 1 is a cutaway view of an electrode cap of the present
invention attached to a plate.

[0011]FIG. 2 is a plan view of the electrode cap without the plate.

[0012]FIG. 3 is a cutaway plan view.

[0013]FIG. 4 is an exploded plan view.

[0014]FIG. 5 is a side elevation of the electrode cap without the plate.

[0017]The invention is an electrode cap comprising a horseshoe-shaped
conductor clip comprising an opening at a closed end for receiving an
electrode, the conductor clip adapted to fit over a tube crimp; a
substantially cylindrical base cap comprising an elongated bump at one
end of the base cap parallel to the axis of the base cap; and a
substantially cylindrical top cap closed on one end, having an inside
diameter larger than the outside diameter of the base cap; and a spring
means for pressing a plate against the base cap.

[0018]Turning to FIG. 1 an electrode tube is provided comprising a tube
114 and an electrode 116 disposed within the tube 114. The tube 114 is
usually hollow, and can be filled with a gas to form a gas filled
electrode ("GFE"). One end of the tube has a crimp 118 that is capable of
containing gas within the tube 114, while the electrode 116 extends
beyond the crimp.

[0019]An electrode cap assembly 100 is provided, that is made up of
several parts. The parts are preferably made of an electrically
conductive material, like stainless steel. First, a conductor clip 108 is
secured to the crimp 118. The conductor clip is horseshoe shaped in cross
section. The closed end of the conductor clip 108 has an opening for
receiving the electrode. The conductor clip 108 is sized to fit over the
crimp 118.

[0020]A base cap 104 is provided. It is substantially cylindrical in that
it has two sections of different diameters. The smaller diameter is sized
to just slide over the outside diameter of the tube 114. The smaller
diameter also has one or more elongated bumps 124a, 124b parallel to the
axis of the base cap 104. These bumps are for locking the electrode
assembly 100 into a plate 112.

[0021]A substantially cylindrical top cap 102 is also provided. The top
cap is closed on one end and open on the other. The inside diameter of
the top cap 102 is sized to have a sliding fit with the outside diameter
of the base cap 104 to provide an electrical connection and inhibit
contamination. Preferably, the junction of the top cap 102 cylinder and
closed end is rounded, as is shown in FIG. 1. The rounded quality
inhibits for the formation of corona.

[0022]A helical compression cap spring 106 can be provided that has an
outside diameter smaller than the inside diameter of the base cap 104.
The cap spring 106 provides electrical connection and compression between
the conductor clip 108 and top cap 102. One can also use a conical
helical spring with the point of the cone contacting the conductor clip
108, or other types of springs that are known in the art.

[0023]A spring means 110 is placed over the base cap 104. The spring means
110 is preferably a wave spring, such as those conforming to DIN 137,
although other springs could be used. Other spring means could be used,
such as a helical spring, conical washer, or Belleville washer.

[0024]The spring means 110 keeps the electrode assembly 100 secure in the
plate 112 after being inserted and twisted to lock it in place. A typical
plate that would be used in this application is 12 gauge stainless steel.
In FIG. 1, a wave spring is shown compressed flat.

[0025]FIG. 2 is a plan view of the electrode assembly 100 without the
plate. The spring means 110 is shown as an uncompressed wave spring. This
view also shows a flap 120 of the base cap 104 that has been received and
secured by a window in the top cap 102.

[0026]FIG. 3 is a cutaway view of the plan view of FIG. 2.

[0027]FIG. 4 is an exploded view of the plan view. The flap 120 of the
base cap 104 can be a rectangular section punched out of the base cap,
and extending outward toward the bump. The window 122 of the top cap 102
is sized to receive and secure the base cap flap 120.

[0028]FIG. 5 is a side elevation of the electrode cap of the present
invention. In this view the configuration of the elongated bump 124a is
shown. The bump is on the end of the base cap 104 with the smaller
diameter, and is parallel to the axis of the base cap. More than one bump
can be provided.

[0029]In this view, details of the base cap flap 120b and window 122a are
shown. Since the flap extends through the top cap 102, the top cap is
locked while under compression. The top cap can be released by
compressing the top cap and pressing in the flap so that it clears the
window. Other mechanisms that are known in the art can be used to secure
the top cap 102.

[0030]FIG. 6 is the cutaway view of FIG. 5, and exposes an elongated bump
124b placed opposite that shown in FIG. 5. It is clear to see how the
conductor clip 108 fits over the crimp 118.

[0031]FIG. 7 is an exploded view of the side elevation. Details of two
base cap flaps 120a, 120b and the top cap windows 122a, 122b are shown in
this view.

[0032]In operation, the electrode assembly is installed by placing a
horseshoe-shaped conductor clip 108 over the crimp 118; securing the
electrode 116 to the conductor clip 108; placing a substantially
cylindrical base cap 104 over the tube 114 at the crimp end, the base cap
104 having an elongated bump 124 at one end of the base cap 104 parallel
to the axis of the base cap, and having an external flap 120 extending
toward the bump 124. Then one places a helical compression cap spring 106
inside the base cap 104 and in contact with the conductor clip 108. Next,
one assembles the top cap 102 so that the base cap flap 120 engages the
top cap window 122 and locks. The next step is assembling a spring means
110 over the base cap 104. Assembling to a plate 112 is completed by
inserting the electrode assembly 100 into the plate 112 having a hole to
receive the base cap 104 and a groove to receive the bump 124 and
twisting the electrode assembly to lock it in place.

[0033]Although the preferred embodiments of the present invention have
been described herein, the above description is merely illustrative.
Further modification of the invention herein disclosed will occur to
those skilled in the respective arts and all such modifications are
deemed to be within the scope of the invention as defined by the appended
claims.